Does bigger ordering fabric width give better fabric consumption?

It looks like it is a known fact that “higher the width of fabric better will give better fabric consumption” but is it really the case?

This will be a discussion post. I just heard a merchandiser quoting that “fabric sourcing must probably order bigger width to save consumption”. It looks like it is a known fact that “higher the fabric ordering width better will be the fabric consumption” but is it really the case? Continue reading “Does bigger ordering fabric width give better fabric consumption?”

Difference Between Standard & Standardised work ?

The question “Difference Between Standard & Standardised work?” has been a confusion for quite a few people and I have seen people particularly pressing on the point that “Do not confuse Standard work with Standardised work”. I googled the difference and what I could understand from many blog posts was that Standard work means the work will not change whereas Standardized work means there is a scope of improvement. Continue reading “Difference Between Standard & Standardised work ?”

Process standardisation- A silver bullet for lean Manufacturing.

“Where there is no standard, there is no Kaizen” . Effective lean strategy should be made by keeping Standardisation as the focus point. This is because Standardised work forms the foundation for Kaizens & is also one of the 5S .

Process Standardisation is a simple technique but with high impact. It is more underestimated than misunderstood. Lean strategy in Garment industry is mainly centered around 5S & Kaizen but an effective lean strategy should be made by keeping Standardisation as the focus point. This is because Standardised work forms the foundation for Kaizens & is also one of the 5S . Taichi Ohno, The father of Toyota Production System himself has famously quoted :

“Where there is no standard, there is no Kaizen”

What is Process Standardisation in garment industry?

Continue reading “Process standardisation- A silver bullet for lean Manufacturing.”

A secret useful excel formula for merchandisers, planners and buyers

In this post I am going to tell you a useful excel formula for merchandisers, planners and buyers ( or every garment professional) which is going to save you a lot of time and will let your boss wondering about your speed and efficiency.

Many a times garment professionals have to copy a style information from one excel sheet to other. To do this, the normally adopted method is to open both the sheets, search the style number , select the style colour then copy the relevant data and paste it into the other sheet. Continue reading “A secret useful excel formula for merchandisers, planners and buyers”

Industrial Engineering Calculations in garment production factory


Industrial engineering calculations in garment production factory is the most powerful waste quantifying and reduction tool.

These calculations are important because without setting up a target it is highly unlikely that you will be able to achieve what is expected. Once the target is set and we know what is expected we can take steps to achieve the target production. It gives industrial engineers clear picture about the performance of sewing operators, supervisors and the sewing line. The things that an industrial engineer needs to calculate are: capacity, efficiency, performance and utilization. Continue reading “Industrial Engineering Calculations in garment production factory”

Doing things right the first time – literature review

Quality is free, what costs money is defects- all the activities resulting from not doing things right the first time. It is always cheaper and efficient to do things right the first time

Doing things right the first time(DRIFT)/Zero defect(ZD)

Doing things right the first time (DRIFT)/Zero defect(ZD) was coined was Philip Crosby in his book Quality is free. According to him Quality is free, what costs money is defects- all the activities resulting from not doing things right the first time. It is always cheaper and efficient to do things right the first time[1] Crosby’s response to the quality crisis was the principle of “doing things right the first time” (DRIFT). Continue reading “Doing things right the first time – literature review”

5S implementation challenges in garment factory

5S implementation challenges in garment factory

5S implementation challenges in garment factory stops the improvement journey before it even starts.. 5S is a slow and gradual process as it involves the support of entire garment factory workforce. There isn’t any magical solution with which you can do it within few months and gain the results. Even if you are able to notice improvements, it won’t sustain for long unless efforts are put to strengthen the 5th S – Sustain Continue reading “5S implementation challenges in garment factory”

Ink Numbering garments panels in assembly sewing line – An efficiency and quality improvement tool

How to implement number sealing on garments in a factory ?

Ink numbering garments is called Number Sealing. Number sealing or Ink numbering refers to printing number on the garment pieces by means of ink and stamping machine to identify the garment panels to be stitched together. It replaces the traditional method of pasting a numbered Sticker on garment pieces Continue reading “Ink Numbering garments panels in assembly sewing line – An efficiency and quality improvement tool”

Fabric saving Cut order plan – characteristics and calculation

Making or choosing a Fabric saving cut order plan can be tricky as there can be hundreds of combinations in a cut order plan. Quite simply a  good fabric cut order plan will require less time and effort for spreading and will use lesser fabric per garment. But there are many factors which make cut order planning efficient as mentioned below , However if you want to understand the basics of how to make a cut order plan , please read this post first.

Characteristics of an efficient Fabric cut order plan :

1. Maximum number of garments on a marker –
Number of garments on marker (G’s ) should be maximum depending on Continue reading “Fabric saving Cut order plan – characteristics and calculation”